Method of and means for forming paper sheets



Feb. 9, 1932.

s. SMITH 1,844,697

METHOD OF- AND MEANS FOR FORMING PAPER SHEETS Filed Feb. 28, 1929 6 Sheets-Sheet l Feb. 9, 1932. s. SMITH 1,844,697

METHOD OF AND MEANS FOR FORMING PAPER SHEETS Filed Feb. 28, 1929 6 Sheets-Sheet 2 Feb. 9, s, SMlTH METHOD OF AND MEANS FOR FORMING PAPER SHEETS Filed Feb. 28, 1929 6 Sheets-Sheet 3 alike wrap Feb. 9, 1932. 5, SMITH 1,844,697

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Feb. 9, 1932. s. SMITH METHOD OF AND MEANS FOR FORMING PAPER SHEETS Filed Feb. 28, 1929 6 Sheets-Sheet 5 I 3 k 9: v8 m 6:, m8

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5. SMITH 1,844,697

METHOD OF AND MEANS FOR FORMING PAPER SHEETS Filed Feb. 28, 1929 6 Sheets-Sheet 6 in shifted position, and in forming the groove from the gathered portion by shifting the Patented Feb. 9, 1932 I TUNITED s rA'rss' PATENT OFFICE SWAN SMITH,-. F WHITE MINNESOTA, ASSIGNOR T0 ORIENDA. CORPORATION, OF

' CHICAGO, ILLINOIS, A CORPORATION OF ILLINOIS Application filed February 28, 1929. Serial No. 343,495.

Myinvention relates to a method of and apparatus for forming sheets and particularly sheets of paper with spaced longitudi- ,nal and spaced transverse grooves, and has for its object to provide a method and apparatus'for forming the said grooves without tearing 0r fracturing. the sheet.

Another object of the invention resides in providing a method and apparatus, whereby .relatively deep and sharp grooves can be formed in'thepaper without injury thereto or weakeningthereof at the said grooves.

An additional object of the invention resides in providing a method of forming the longitudinal grooves in which the sheet is gathered atthe locus of the groove by shifting a portion of thesheetat one side of the locus-of the groove out of the. plane of the sheet, in retaining the part of the shifted or gathered portion of the sheet at the groove remainder of the gathered portion back into the plane of the sheet.

Another object of the invention resides 1n providing a methodof forming transverse and longitudinal grooves which consists in first contemporaneously forining the longitudinal grooves and in subsequently forming the transverse grooves individually.

A further object of the invention resides in providing a method of forming sheets in which the longitudinal grooves are formed progressively, the sheet being successively gathered from the-edges thereof towards the :center to successively formthe longitudinal grooves.

A still further object of the invention re-- sides inproviding a method of forming the grooves which consists in forming the longitudinal grooves, then preheating the sheet,

and then simultaneously heating the sheet and forming the transverse grooves therein.

An object of the invention resides in providing a. machine havinga number of pairs of cooperating rolls between which a sheet is passed, said rolls beingformed'with shoulders for gathering the paper from an edge 7 thereof.

. Another object of the invention resides in providing the successive rolls with beads in line with preceding gathering shoulders, which are adapted to form the grooves in the sheet along the lines of the gathered material.

* A further object of the invention resides in arranging the forming shoulders and beads for the various grooves on successive rolls and in disposing each subsequent set of shoulders and beads in spaced lateral position with respect to the preceding set so as to initiate the formation of the grooves, one after the other, beginning with the first of the series of cooperating rolls.

An object of the invention residesin providing a pair of drums having groove forming members thereon extending longitudinally of said rolls for forming the transversegrooves in the sheet.

, Another object of the inventionresides in heating the drums to set the sheet as it leaves the machine.

A still further object of the invention resides in providing auxiliary heating means disposed between said rolls and drums for preheating the sheet prior to its introduction to said drums.

With the foregoing and other objects in view, .whichwill appear in the following description, the invention resides in the novel ,combination and arrangement of parts and in the details of construction hereinafter described and claimed. In the drawings:-

- Fig. 1 is a plan view of a machine illustrating a structural embodiment of the invention.

Fig. 2is an elevational sectional view taken on line 2-2 of Fig. 1.

Fig. 3 isa side elevational view of the structure shown in Fig.1. I Fig. 4 is an elevational sectional view taken on .line 4-4 of Fig. 1.

Fig. 5 is'an elevational sectional view taken on line .5 5 of Fig. 1.

Fig. 6 is a fragmentary elevational sectional view taken on line 66 of Fig. 1 show-. ing' the drive for the forming rolls.

Fig.7 is a fragmentary taken on line 77 of Fig. 3.

Fig. 8 is an enlarged fragmentary elevaplan sectional view 1 tional view of the first pair of forming rolls showing the method of gathering the sheet.

Fig. 9 is a similar view illustrating the second pair of forming rolls and showing the a method of forming the first two grooves and of gathering the sheet for the two grooves particularly useful in the construction of egg flats such as shown in detail in Fig. 12. In the packing of eggs for shipment, it is desirable to employ sectional dividers in connection with grooved sheets or flats, such as illustrated in Fig. 12. Heretoforc, no means or method has been available for the satisfactory production of flats of this character. in quantity, at a cost commercially acceptable. and none in which such flats may be produced continuously from a roll of ordinary paper. The present invention contemplates particularly the contiguous formation of the flats from rolled paper stock of a relatively lIl8X- pensive grade.

In Fig. 12, 61 designates the sheet from which the egg flats are made, while the longitudinal grooves in the sheet have been numbered 62 and the transverse grooves 63. These grooves are spaced apart a distance equal to the distance between the adjacent portions of the well-known dividers with which the flats are to be used and a suflicient" number of grooves are formed in each flat to correspond with the number of sections of the divider. The egg flats are preferably constructed of paper and with my improved method and machine, I am able to utilize a relatively inexpensive grade of paper, which is fed directly into my machine in moistened condition from a paper making machine or from a roll of stock after being moistened to render it more or less pliable. As the paper enters my improved machine, it is gathered from the sides to form the longitudinal grooves. It is then preheated and subsequently passed through heated drums to form the transverse grooves.

A device representing an embodiment of the invention, and with which my improved method may be-carried out, is shown in detail in the drawings. This device includes two longitudinal frame members 10 and 11 which are connected bv means of four transverse bars 12. 13.14 and 15 secured to saidlongiand 24, and immediately above them are rotatably mounted eight complemental rolls 25, 26, 27, 28, 29, 30,- 31 and 32. These rolls are arranged in pairs with the peripheries thereof adjoining in a common plane. Each of the rolls 17 to 24, inclusive, is formed with trunnions 33and34 (Fig. 4) which are journaled in bearings 35 on the frame members 10 and 11. The upper rolls to 32, inclusive, are similarly constructed with trunnions 36 and 37 journaled in bearings 38 which are movable within openings 47, formed in the frame members 10 and 11 directly above the bearings 35, in a manner to be moved toward or from the said bearings to vary the dis tance between the respective rolls of the different pairs of rolls. The bearings 38 are constructed with vertical slots 39, as best shown in Fig. 7. These slots slidably fit the guides 40 and 41 formed by the frame members 10 and 11 adjacent to the openings 47. The respective rolls of the different pairs are normally held apart by means of coil springs 42 (Fig. 4) which are seated in sockets 43 in bearings 38 and in corresponding sockets 44 'in the frame members 10 and 11, immediately below the sockets 43. By applying pressure to the upper portions of the bearings 38, the same may be forced downwardly toward the bearings 35, along the guides 40 and 41, in opposition to the springs 42 to vary the distance between the respective rolls of the various pairs.

For the purpose of maintaining the rolls in adjusted posit-ion, each of the frame members 10 and 11 is provided with a longitudinal bar 45 resting upon the upper edge thereof and closing the openings 47 therein. These bars are secured to said frame members by means of bolts 46 screwed into the portions of the frame members between the openings 47 therein. Centrally disposed with respect-to said openings 47 are adjusting 'sc'rews 48, each being threaded in its respective bar 45 in a manner to engage the particular bearing 38 immediately below the same. ,By turning these screws 48 in one direction, the bearings 38 may be forced toward the bearings 35 in opposition to springs 42, and by turning said screws in the opposite direction, reverse movement of said bearings may be had through said springs so that the rolls may be quickly and accurately adjusted relative to one another, at will. olding the adjusting screws 48 in locked position are lock nuts 49 threaded upon said adjusting screws and adapted to seat against the bars 45.

The various rolls 17 to 24, inclusive, are all driven in a counter-clockwise direction, as

viewed in Fig. 2, and at the same rate of speed. The rolls 25 to 32, inclusive. are

driven. in a clockwise direction and at the 'less than the space between the shoulders 52 and 53, and is positioned with respect to the rings and 51 so that the shoulders thereof overlap, as clearly shown in Fig. 8. As a sheet or strip is inserted between the two rolls 32 and 24, the center thereof, as at 57, is gripped between the ring 54 and a bearing rings 50 and 51. This feeds or advances the sheet between the paired rolls 32, 24, while the shoulders 52, 53, 55 and 56 coact to gather the sheet from the two sides and draw the stock inwardly to form offset portions in the sheet indicated at 59 and 60 respectively. It will be noted that the distance between the bearing surface 58 and the periphery of the ring 54 is such as to cause the sheet to be firm- 1y gripped and fed between the rolls, while the spaces between the shoulders 53 and 56, the shoulders 52 and 55 and the peripheries of the rings 50, 51 and the periphery of the roll 24 are such as to permit the sheet or strip to pass readily therethrough and be formed as indicated in Fig. 8.

The roll 31 (Fig. 9) ,.next succeeding roll 32, is provided with two annular beads'64 .and of-peripheral shape and form corresponding with the finished grooves 62 of the eggflat 61. These beads 64, 65 are arranged in alignment with the rings 50 and 51 and operate, in the formation of said grooves 62, in a manner to utilize the stock gathered by the offset rings 50, 51 and 54. In the formation of these grooves, T sufficient stock is gathered, during the passage of the sheet between the rolls 32 and 24. so that the grooves 62 may be finally formed by reversely-shifting the shifted portion of the sheet to the original plane of the sheet, as indicated at 67 and 68 in Fig. 9. In-the formation of the grooves 62, the beads 64 and 65 co-operate with grooves 69 and 70 formed in the roll 23. The feeding of the'sheet or strip between the rolls 31 and 23 is effected by means ofbearing surfaces 71 and 72 which are formed on the roll 31 and gripthe sheet against the periphery of the roll 23. While the sheet is being fed between these two rolls 31, 23, additional stock is being gathered from the sides of the sheet preparatory to the formation of the next two grooves. This is accomplished by means of rings 73 and 74 which are formed with facing shoulders .7 6

1 similar to shoulders 52 and 53 on rings 50 and 51. The roll 23 is turned down to form two shoulders 77 and 78 like the shoulders 55 and 56 (Fig. 8). Said shoulders 77 and 78 bear the same relation to the shoulders and 76 as exists between the shoulders 55, 56 and 52, 53 and they function in the same manner to gather the stock from the sides of the sheet or strip and toprovide offset portions 79 and 80 in the same. The next set of rolls 22 and 30 are constructed the same as rolls 23 and 31 except that they are provided with beads sinflar tobeads 64 and 65 in line with the rings 73 and 74 and with additional beads in line with the said beads 64 and 65. It will now be'understood that the successive sets of rolls provide for the gathering of the stock from the sides 'of the sheet and that the [formation of the different pairs of grooves is surface 58 formed on the roll 32 between the;

initiated consecutively as the sheet moves through the successive rolls. Fig. 4, illustrating the last of the gathering rolls 18 and tioned-shou'lders, which gather the stock from the sides of the sheet for the formation of the outermost grooves therein. The rolls 17 and 25 are constructed with beads alone, as best shown in Fig. 1, the outermost beads serving to finally form the outermost grooves in the sheet. With this construction, it will' be noted that the formation ofthe grooves is progressively initiated as the sheet passes through the device and between the various pairs of rolls, and that the sheet is positively fed through each pair of rolls, between the bearing surfaces provided at the rolls adjacent the gathering shoulders thereon. When the sheet leaves the last pair of rolls 17 and 25, it is properly formed with equally spacedlongitudinal grooves and is relatively moist.

The sheet, upon leaving rolls 17 and 25,

next passes between two heated drums 84 and 85 by means of which the formed sheet is partially set and preheated in advance of its entry between two heated forming drums 94 and 95 which form the transverse grooves and which are best shown in detail in Figss2. 3

and 5. The construction and mounting of the drums 94 and 95, being similar to that of the drums 84 and 85, a detailed description of the drums 94 and 95 alone will sufiice. The drum 94 (Fig. 5) includes a hollow cylindrical portion 96 having ends 97 and 98. These'ends 97 and 98 are formed with hollow trunnions 101 and 102 journaled inbushings 103 and 104 mounted in the frame members 10 and 11. The trunnions 101 and 102 are provided with central bores 1 05 and 106 through one of i which an elongated gas burner 1071's inserted into the interior of the hollow cylinder 96 and by means. of which the drum may be heated to a suitable temperature. The opening through the opposed trunnion, together with a number of vents 108, formed in the ends 97 and 98, admit sufficient air to support combustion at the burner 107 and at the same time permit of the escape of the. gases of combustion. As the drum 91 rotates, it is uniformally heated throughout its extent by the burner 107, as will readily become apparent.

The drum 95, like the drum 91, includes a hollow cylindrical portion 96 and ends 97 and '98. These ends have hollow trunnions 109 and 110 journaled in bearing blocks 111 and 112, situated within openings 113 in the frame members 10 and 11. These bearing blocks 111. 112 are formed with slots 111 and 115 (Fig. 7) along their vertical edges which receive guiding portions 116 and 117 of the side frames along the edges of the openings 113. The drum 95 is normally forced upward from the drum 91 by means of two comdrums 91 and 95 and include hollow cylinder portions 86 with ends 87 having hollow trunnions 88 issuing outwardly therefrom. The trunnions 88 of drum 81 are ournaled in the frame members 10 and 11, while the trunnions 88 of the drum are journaled in hearing blocks 89 (Fig. 3). These bearing blocks are disposed within openings 90 in the frame members'lO and 11 and are formed withslots 91 cooperating with guides 92. Compression coil springs interposed between the blocks 89 and frame members 10 and 11 serve to force the drum 85 upward from the drum 81, the same as drum 95 is forced upward from drum Adjustment of the two drums 95 and 85 is accomplished as follows: Attached to the upper portions of the frame members 10 and 11 are two bars 10 and 11 which are rigidly secured to said frame members by-means of cap screws 121. These bars cover the openings 90 and 113 in the frame members and are 'tapped to receive adjusting screws 122 and 123 (Figs. 3 and 5) which engage the upper surfaces of the bearing blocks 89 and 112 and force the samedownwardly against the'action of springs 118 an :1 93 to'move the drums 95 and 85 towards the drums 91 and 81.

These adjusting screws may be locked in ad- 'justed position by means of lock nuts 121 drum 81. The trunnions 88, as previously specified, are formed with central bores 127 adapted to receive gas burners 128 identical with the gas burners 107 used in conjunction with drums 91 and 95. These gas burners 128 i it becomes heated thereby and partially set.

At the same time, sufficient heat is imparted to a strip or to sheets so that they may be .passed through the machine more rapidly than would be the case if the entire heating of the same were accomplished solely through the drums 91 and 95. The use of drums 81 and 85 further prevents the flattening out of the longitudinal grooves formed in the stock by the rolls 17-32 so that a uniform and perfectly formed groove structure is provided. The roll 95, as best shown in Fig. 10,'is constructed with a number of longitudinal beads 130 which cooperate with corresponding longitudinal grooves 131formed in the peripheral surface of the drum 91. As the two drums 91 and 95 rotate, the sheet being fed between said drums is finally formed with transverse grooves as at 63. Fig. 12.

In order to retain the shape and form ofprovide for suitable ventilation of the device.

As. the stock passes between the hot drums 91 and 95, it becomes set by the heat imparted thereto and retains its form after the sheet leaves the machine.

The surplus stock at the intersections ofthe longitudinal and transverse grooves is compacted and flattened out during the formation of the latter grooves (Fig. 12) so that a series of uniform intersecting grooves is formed in the finished sheet. By first constructing the longitudinal grooves and then the transverse. grooves, in the manner disclosed inethis application, the paper is at no time under tension, and the danger of fracturing or tearing it is entirely eliminated. The formed stock readily retains its shape and the structure formed is of maximum strength. Obviously, the paper used may be of relatively inferior grade. The illustrated embodiment of the invention accommodates sheets or strips of double width, suflicient rolls being provided to construct tw'o egg flats side by side. The formed sheet or strip is split medially after leaving the drums 94 and 95 by means of two cutter rolls 135 and 136. These rolls are preferably journaled in the same manner as the rolls 17 and 32 inclusive, and the supporting structure thereof will hence not be-described in detail. Said rolls, however, are provided with a pair of circular cutters 139 and 140 which cut the formed sheet on a medial line. The said rolls 135, 136 are further provided with outside cutters 141, 142 and 143, 144, which trim the edges of the sheet or strip as it leaves the drums 94 and 95, and as it is automaticallv slit in the. middle by the said cutters 139, 140. The method of driving the various rolls and drums is best shown in Figs. 3, 5 and 6. The trunnion 101 of drum 94 is provided with a spur gear 147 which meshes with a corre-. sponding spur gear 148 fasten the trunnion 109 of drum 95. The entire machine may be operated through suitable gearing or other power transmission devices connected to the gear 147 or to any of the other various gears utilized in the machine.

' Through .the agency of the two gears 147 and 148, the two drums 94 and 95 are driven in opposite directions so as to positively feed the sheet or strip therethrough. The trun nion 102 of the drum 94 has attached toit a spur gear 145, while the trunnion 88 of-drum 84 has similarly attached to it a spur gear 146-. These gears mesh with a common idler gear 149 which is journaled on a stud 150 secured to the frame member 11. As the drum 94 is rotated through the agency of the gear 145, drum 84 is simultaneously rotated.

Both of the drums 84 and 85 may be geared to one another by means of intermeshing spur gears 152 attached to the ends of the trunnions 88 thereof, the same as the gears 147 and 148 of drums 94 and 95. In this manner all four drums may be similarly rotated in the properdirection to progressively feed the sheet between them as the machine operates. Although the upper drums 95 and 85 are adjustable with respect to the" lower drums, the adjustment does not interfere with the operation of the driving gears, which, preferably, have elongated gear teeth of cycloidal form.

The method of driving the rolls 17 to 32 is best shown in Fig. v6. To .each of the trunnions 34 of rolls 17 to 24 inclusive, is attached a spur gear 154. A similar spur gear 155 is attached to the trunnion 37 of each of the rolls 25 to 32, inclusive. The respective spur gears of each pair of rolls mesh with one another to compel the simultaneous rotation of the rolls in opposite direction to feed the stock therebetween. Simultaneous driving of all of the rolls of the device is accomplished through a series of idler gears 156 which mesh with adjoining gears 154 and which are ournaled on studs 157 mounted in the frame member 11. The trunnion 34 of the roll 17 (Fig. 3) projects outwardly beyond its hearing 35 and has attached to it a spur gear 158. This gear meshes with an idler gear 159 rotatably mounted on a stud 160 secured to the frame 11. This idler gear also meshes with the gear 146 uIl trunnion 88 of drum 84so that simultaneous rotation all of the rolls in the proper direction is to be had upon rotation of the said drum 84.

The cutter rolls 135 and 136 may be driven through two intermeshing spur gears 161 secured to the extending portions of the trunnions 137 and 138 thereof at the same end of the machine as the gears 147 and 148 of drums 94 and 95 are located. A drive is effected through a spur gear 162 (Fig. 3) which is secured to the protruding end of the trunnion 137 of roll 135, which gear meshes with an idler spur gear 163 mounted upon a stud 164 attached to frame member 11. This idler gear also meshes with the spur gear 145 through which power is imparted to the machine. Upon the rotation of said gear 145 all of the drums and rolls of the machine are simultaneously rotated in the proper direction. By selecting the proper sizes of gears, the pe; ripheral,. velocity of all of the rolls and drums can be so proportioned that the sheet is progressively moved through the machine without tearing. 'Dueto'the fact that the transverse grooves are formed by the last pair of all of the preceding rolls can be ardrums, ranged to travel at substantially the same velocity, though slight variations may be made in the speed thereof to compensate for slippage and distortion of the sheet. The two drums 94 and 95, however, are driven at a slightly lower peripheral velocity than the preceding drums and rolls in order to provide sufficient slack in the stock to form the transverse grooves in the sheet. The two cutter rolls 135 and 136 are geared to travel at a peripheral speed equal to that of the drums 94 and 95.

In the use of my improved method and apparatus, a moistened strip is fed into the machine. As-this strip passes through the machine, it is first formed with longitudinal grooves, then preheated and next formed with transverse grooves. During said last operation, the stock is set by further heating. Upon leaving the machine, the sheets or strips are split medially thereof and trimmed at their outer edgesf Thereafter, the stock is suitably cut crosswise and thus finally reduced to its ultimate dimensions.

-My invention is highly advantageous in that the finished product can be manufactured rapidly and at a minimum cost. Paper of a relatively inexpensive grade may be utilized and formed without the tearing or weakening of the stock. The machine is extremely simple and will notreadily get out of order, and

sheets which consists in shifting that portion of the sheet to one side of the locus of the groove out of the plane of the sheet, re-

taining part of the shifted portion of the sheet at the groove in shifted position, and in shifting the remainder of the shifted portion back into the plane of the sheet.

2. The method of forming sheets with a plurality of longitudinal and a plurality of transverse grooves, which consists in passing the sheets between a number of rolls to form the longitudinal grooves, heating the sheets to partially set the longitudinal grooves and in further heating the sheets and forming the transverse grooves therein.

3. In a machine for forming sheets with longitudinal grooves, successive pairs of com plemental rolls between which the sheet is adapted to pass, each pair of rolls having overlapping shoulders formed thereon for gathering the sheet sidewise, and each .successive pair of rolls being formed with complemental beads and grooves for forming the gathered portions of the sheet into grooves.

4. In a machine for forming sheets with longitudinal grooves, successive pairs of rolls between which the sheet is adapted to pass, overlapping shoulders formed on complementary, rolls of each pair for gathering the sheet sidewise, and each successive pair-of rolls being formed with complemental beads and grooves for forming the gathered portions of the sheet into grooves, the shoulders of the succeedingpairs of rolls being progressively disposed sidewise in respect to'each other.

5. A machine for forming a sheet with longitudinal and transverse grooves comprising a number of pairs of, complemental rolls and a pair of drums between which the sheets are adapted to pass, means on said rolls for first forming a plurality of longitudinal grooves in the sheet, said means being adapted to initiate the formation of-said grooves progressively, laterally of the sheet, and means on said drums for forming transverse grooves in said sheet.

6. A machine for forming a. sheet with longitudinal and transverse grooves comprising a pair of rotary forming members between which said sheet is adapted to pass, circumferentially disposed forming means on said forming members for forming longitudinal grooves in said sheet as the same passes between said members a second an of rotar forming members, and forming means thereon extending in a longitudinal direction along the peripheries thereof for forming transverse grooves in said sheet.

7. The method of forming sheets with parallel grooves which consists in moving the sheet in a given direction, restraining a flat portion of the sheet from lateral movement with respect to its movement in said given direction along a lineal zone of said sheet, gathering the sheet laterally along other zones paralleling said restrained zone, and in initiating said gathering process along said other zones progressively away from said restrained zone.

8. A machine for forming a sheet with longitudinal grooves comprising successive pairs of rolls between which the sheet is adapted to' pass, overlapping shoulders formed on complementary rolls of each pair for gathering the sheet sidewise, each successive pair of rolls being formed with complemental beads and grooves so shaped and located as to form into grooves the portions of the sheet gathered by the preceding rolls, the shoulders of the succeeding pairs of rolls being progressively disposed sidewise in respect to each other.

9. In a machine for forming sheets with longitudinal grooves, successive pairs of rolls between which the sheet is adapted to pass, overlapping shoulders formed on each pair for gathering the sheets sidewise, and each successive pair of rolls being formed with complemental beads and grooves in line with the preceding shoulders for forming into grooves the portions of the sheet which were gathered at said shoulders. the shoulders of the succeeding pairs of rolls being progressively disposed sidewise in respect to each. other.

In testimony whereof Iv have af'fixed my signature to this specification.

'SVVAN SMITH. 

